Rapid heating of sheet metal blanks for stamping

ABSTRACT

Systems and methods of hot forming a metal blank include receiving the metal blank at a heater and positioning the blank adjacent a magnetic rotor of the heater. The systems and methods also include heating the metal blank through the magnetic rotor by rotating the magnetic rotor. Rotating the magnetic rotor induces a magnetic field into the metal blank such that the metal blank is heated.

The present application claims the benefit of U.S. Provisional PatentApplication No. 62/400,426 entitled “ROTATING MAGNET HEAT INDUCTION” andfiled on Sep. 27, 2016, and U.S. Provisional Patent Application No.62/505,948 entitled “ROTATING MAGNET HEAT INDUCTION” and filed on May14, 2017, the disclosures of which are hereby incorporated by referencein their entireties.

Additionally, the present application is related to U.S. Non-provisionalpatent application Ser. No. 15/716,692 to David Anthony Gaensbauer etal., entitled “MAGNETIC LEVITATION HEATING OF METAL WITH CONTROLLEDSURFACE QUALITY” filed Sep. 27, 2017, and U.S. Non-provisional patentapplication Ser. No. 15/716,887 to Antoine Jean Willy Pralong et al.,entitled “ROTATING MAGNET HEAT INDUCTION” filed Sep. 27, 2017, thedisclosures of which are hereby incorporated by reference in theirentirety.

FIELD OF THE INVENTION

This application relates to metal processing and, more particularly,systems and methods for rapid heating of metal blanks for hot forming.

BACKGROUND

Many applications may utilize metal products such as aluminum oraluminum alloys. As one example, metal products may be used intransportation applications, including automotive, aircraft, and railwayapplications. For example, metal products can be used to prepareautomotive structural parts, such as bumpers, side beams, roof beams,cross beams, pillar reinforcements, inner panels, outer panels, sidepanels, inner hoods, outer hoods, or trunk lid panels. As anotherexample, metal products may be used in electronics applications. Forexample, metal products can be used to prepare housing for electronicdevices, including mobile phones and tablet computers. In some examples,metal products can be used to prepare housings for the outer casing ofmobile phones (e.g., smart phones), tablet bottom chassis, and otherportable electronics.

Various forming techniques may be employed to form the metal productshaving a particular shape. One such forming technique is hot forming orpressing. While hot forming may be used to shape various blanks, such asblanks of aluminum or high strength steel, a hot forming process withshorter cycle times to increase productivity and reduce costs associatedwith the hot forming process can be desired.

SUMMARY

The terms “invention,” “the invention,” “this invention” and “thepresent invention” used in this patent are intended to refer broadly toall of the subject matter of this patent and the patent claims below.Statements containing these terms should be understood not to limit thesubject matter described herein or to limit the meaning or scope of thepatent claims below. Embodiments of the invention covered by this patentare defined by the claims below, not this summary. This summary is ahigh-level overview of various embodiments of the invention andintroduces some of the concepts that are further described in theDetailed Description section below. This summary is not intended toidentify key or essential features of the claimed subject matter, nor isit intended to be used in isolation to determine the scope of theclaimed subject matter. The subject matter should be understood byreference to appropriate portions of the entire specification of thispatent, any or all drawings, and each claim.

According to certain examples, a hot forming system includes a heaterhaving a magnetic rotor. In various examples, the heater is configuredto receive a blank of a metal substrate adjacent the magnetic rotor androtate the magnetic rotor to induce a magnetic field in the blank toheat the blank.

According to certain examples, a method includes receiving a blank of ametal substrate at a heater and positioning the blank adjacent amagnetic rotor of the heater. In some examples, the method includesrotating the magnetic rotor to induce a magnetic field in the blank toheat the blank for a predetermined time period.

According to certain examples, a method includes receiving a blank of ametal substrate at a heater. In certain examples, the heater includes amagnetic rotor. In some examples, the method includes positioning theblank adjacent the magnetic rotor of the heater. In various examples,the method includes rotating the magnetic rotor to induce a magneticfield in the blank to heat the blank. In some cases, the method includesremoving the blank from the heater when the blank is at a predeterminedtemperature.

Various implementations described in the present disclosure can includeadditional systems, methods, features, and advantages, which cannotnecessarily be expressly disclosed herein but will be apparent to one ofordinary skill in the art upon examination of the following detaileddescription and accompanying drawings. It is intended that all suchsystems, methods, features, and advantages be included within thepresent disclosure and protected by the accompanying claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and components of the following figures are illustrated toemphasize the general principles of the present disclosure.Corresponding features and components throughout the figures can bedesignated by matching reference characters for the sake of consistencyand clarity.

FIG. 1 is a perspective schematic view of a hot forming system includinga heater according to aspects of the current disclosure.

FIG. 2 is a side schematic view of the system of FIG. 1.

DETAILED DESCRIPTION

The subject matter of examples of the present invention is describedhere with specificity to meet statutory requirements, but thisdescription is not necessarily intended to limit the scope of theclaims. The claimed subject matter may be embodied in other ways, mayinclude different elements or steps, and may be used in conjunction withother existing or future technologies. This description should not beinterpreted as implying any particular order or arrangement among orbetween various steps or elements except when the order of individualsteps or arrangement of elements is explicitly described.

Many metalworking techniques may be used to form a blank or strip of amaterial into a final desired shape for various applications such astransportation and automotive, electronics, and various otherapplications. One such metalworking technique for blanks or strips ofmaterial such as high strength steel and aluminum is hot forming. Duringhot forming, a blank, such as a blank of steel or aluminum or othermaterial, is positioned into a hot forming press, and a die surfaceshapes the blank as the blank is pressed by the hot forming press.Oftentimes, to facilitate the hot forming process, the blanks are heatedprior to pressing. However, conventional heaters require longer cycletimes to adequately heat the metal blanks. For example, conventionalheaters typically require about 10-20 minutes to heat up aluminum blanksdepending on the size and thickness of the aluminum blank. Thisprolonged heat up time results in a longer overall cycle time of theblank, which increases the costs associated with the hot formingprocess.

Disclosed are systems and methods for hot forming of a blank andpreparing a blank for hot forming. In some examples, the systems andmethods include using magnetic heating to preheat the blank before hotforming. Aspects and features of the present disclosure can be used withvarious suitable metal blanks, and may be especially useful with metalblanks of aluminum or aluminum alloys. Specifically, desirable resultscan be achieved when the metal blanks are alloys such as 2xxx series,3xxx series, 4xxx series, 5xxx series, 6xxx series, 7xxx series, or 8xxxseries aluminum alloys. For an understanding of the number designationsystem most commonly used in naming and identifying aluminum and itsalloys, see “International Alloy Designations and Chemical CompositionLimits for Wrought Aluminum and Wrought Aluminum Alloys” or“Registration Record of Aluminum Association Alloy Designations andChemical Compositions Limits for Aluminum Alloys in the Form of Castingsand Ingot,” both published by The Aluminum Association.

Reference is made in this application to alloy temper or condition. Foran understanding of the alloy temper descriptions most commonly used,see “American National Standards (ANSI) H35 on Alloy and TemperDesignation Systems.” An F condition or temper refers to an aluminumalloy as fabricated. An O condition or temper refers to an aluminumalloy after annealing. A T4 condition or temper refers to an aluminumalloy after solution heat treatment (i.e., solutionization) followed bynatural aging. A T6 condition or temper refers to an aluminum alloyafter solution heat treatment followed by artificial aging. A T7condition or temper refers to an aluminum alloy after solution heattreatment and then followed by overaging or stabilizing. A T8 conditionor temper refers to an aluminum alloy after solution heat treatment,followed by cold working and then by artificial aging. A T9 condition ortemper refers to an aluminum alloy after solution heat treatment,followed by artificial aging, and then by cold working. An H1 conditionor temper refers to an aluminum alloy after strain hardening. An H2condition or temper refers to an aluminum alloy after strain hardeningfollowed by partial annealing. An H3 condition or temper refers to analuminum alloy after strain hardening and stabilization. A second digitfollowing the HX condition or temper (e.g. H1X) indicates the finaldegree of strain hardening.

Aspects and features of the present disclosure include hot formingsystems and methods having a heater that includes one or more magneticrotors arranged above and/or below a blank to induce moving or timevarying magnetic fields through the blank. The changing magnetic fieldscan create currents (e.g., eddy currents) within the blank, thus heatingthe blank.

In some cases, the magnetic rotors disclosed herein may be used withnon-ferrous materials, including aluminum, aluminum alloys, magnesium,magnesium-based materials, titanium, titanium-based materials, copper,copper-based materials, steel, steel-based materials, bronze,bronze-based materials, brass, brass-based materials, composites, sheetsused in composites, or any other suitable metal, non-metal orcombination of materials. The article may include monolithic materials,as well as non-monolithic materials such as roll-bonded materials, cladmaterials, composite materials (such as but not limited to carbonfiber-containing materials), or various other materials. In onenon-limiting example, the magnetic rotors can be used to heat metalarticles such as aluminum metal strips, slabs, blanks, or other articlesmade from aluminum alloys, including aluminum alloys containing iron.

Each magnetic rotor includes one or more permanent magnets orelectromagnets. In some examples, a pair of matched magnetic rotors canbe positioned on opposite sides of a passline of the blank. In otherexamples, one or more magnetic rotors are positioned above or below thepassline. The magnetic rotors are rotatable in a forward direction or areverse direction, and may be rotated through various suitable methodsincluding, but not limited to, electric motors, pneumatic motors,another magnetic rotor, or various other suitable mechanisms. Thedirection and rotational speed of the magnetic rotors may be adjustedand controlled as needed. In some examples, the magnetic rotors arepositioned a predetermined distance from the passline. In certain cases,the distance between the magnetic rotors and the passline may beadjusted and controlled as needed.

Precise heating control for hot forming treatment can be achieved whenusing the heater. Such precise control can be achieved throughmanipulation of various factors, including strength of magnets in therotor, number of magnets in the rotor, orientation of magnets in therotor, size of magnets in the rotor, speed of the rotor, the directionof rotation in the forward direction or reverse direction, size of therotor, vertical gap between vertically offset rotors in a single rotorset, laterally offset placement of rotors in a single rotor set,longitudinal gap between adjacent rotor sets, thickness of the blankbeing heated, distance between the rotor and the blank, forward speed ofthe blank being heated, and number of rotors sets used. Other factorscan be controlled as well. In some cases, the heater is a fast responseheater because the rotation of the magnets may be stopped and starteddepending on whether a metal blank is within the heater to quickly heator stop heating a metal blank. In some cases, control of one or more ofthe aforementioned factors, among others, can be based on a computermodel, operator feedback, or automatic feedback (e.g., based on signalsfrom real-time sensors).

As used herein, the terms “above,” “below,” “vertical,” and “horizontal”are used to describe relative orientations with respect to a metal stripor blank as if the metal strip or blank were moving in a horizontaldirection with its top and bottom surfaces generally parallel to theground. The term “vertical” as used herein can refer to a directionperpendicular to a surface (e.g., top or bottom surface) of the metalstrip or blank, regardless of the orientation of the metal strip orblank. The term “horizontal” as used herein can refer to a directionparallel to a surface (e.g., top or bottom surface) of the metal stripor blank, such as a direction parallel to the direction of travel of amoving metal strip or blank, regardless of the orientation of the metalstrip or blank. The terms “above” and “below” can refer to locationsbeyond top or bottom surfaces of a metal strip, regardless of theorientation of the metal strip or blank.

An example of a hot forming system 100 for blanks 102 is schematicallyillustrated in FIGS. 1 and 2. Although the system 100 is described as ahot forming system, it will be appreciated that the system 100 may alsobe a warm forming system where the forming temperatures are not as highas in the hot forming system.

As illustrated in FIGS. 1 and 2, the hot forming system 100 includes aheater 104 and a hot forming press 106. In some examples, the hotforming system 100 includes a blank mover 108. The heater 104 may beorientated in various directions relative to the ground, such asvertically, diagonally, or horizontally, and is not limited to theorientation shown in FIGS. 1 and 2. For example, the heater 104 may beoriented vertically (and the blank 102 passes vertically through theheater 104), diagonally (and the blank 102 passes through the heater 104at an angle relative to the ground), horizontally, or various otherorientations or combinations of orientations.

In some examples, the hot forming system 100 optionally also includes asecond heater 110. During a hot forming process, the blank 102 is heatedby the heater 104, optionally heated by the second heater 110, moved tothe hot forming press 106 by the blank mover 108, and formed into apredetermined shape using the hot forming press 106.

As illustrated in FIGS. 1 and 2, the heater 104 includes at least onemagnetic rotor 112, and in certain examples, the heater 104 includesmore than one magnetic rotor 112. For example, the heater 104 mayinclude one magnetic rotor 112, two magnetic rotors 112, three magneticrotors 112, four magnetic rotors 112, five magnetic rotors 112, sixmagnetic rotors 112, or more than six magnetic rotors 112. As such, thenumber of magnetic rotors 112 should not be considered limiting on thecurrent disclosure. In the non-limiting example illustrated in FIGS. 1and 2, the heater 104 includes two magnetic rotors 112.

Each magnetic rotor 112 includes one or more permanent magnets orelectromagnets. The magnetic rotors 112 are rotatable (see arrows 122 inFIG. 2) in a forward direction (a clockwise direction in FIG. 2) or areverse direction (a counter-clockwise direction in FIG. 2). In variousexamples, the magnetic rotors 112 may be rotated through varioussuitable methods including, but not limited to, electric motors,pneumatic motors, another magnetic rotor, or various other suitablemechanisms.

The magnetic rotors 112 are spaced apart from the passline of the blank102 such that, during processing, the magnetic rotors 112 are in anon-contacting configuration with the blank 102. In various examples,the magnetic rotors 112 are vertically adjustable such that a distancebetween a particular magnetic rotor 112 and the blank 102 (or passlineof the blank 102) may be adjusted and controlled.

In some examples, the magnetic rotors 112 are provided as a set having atop magnetic rotor 112A positioned above the passline and a bottommagnetic rotor 112A positioned below the passline. In other examples,the heater 104 includes only bottom magnetic rotors 112B, only topmagnetic rotors 112A, or various combinations of top magnetic rotors112A and bottom magnetic rotors 112B. In some examples, at least one topmagnetic rotor 112A is horizontally aligned with a corresponding bottommagnetic rotor 112B, although it need not be. In certain examples, thetop magnetic rotor 112A is vertically offset from a corresponding bottommagnetic rotor 112B such that a gap 128 (FIG. 2) is defined between themagnetic rotors 112A-B. As illustrated in FIGS. 1 and 2, duringprocessing, the blank 102 is passed through the gap 128. In other cases,the top magnetic rotor 112A may be horizontally offset relative to abottom magnetic rotor 112B.

In various examples, the top magnetic rotor 112A and the bottom magneticrotor 112B are vertically adjustable such that a size of the gap 128,which is a distance from the top magnetic rotor 112A to the bottommagnetic rotor 112B, may be adjusted and controlled (see arrows 126 inFIG. 2). In various examples, the gap 128 may be controlled throughvarious actuators including, but not limited to, hydraulic pistons,screw drives, or other suitable examples. In certain examples, the gap128 may be varied between a minimum gap size and a maximum gap size. Insome cases, the strength of the magnetic field, and thus the amount ofheat imparted into the blank 102, may be controlled by changing thedistance between the magnetic rotors 112A-B and the blank 102. Invarious examples, the top magnetic rotor 112A may be verticallyadjustable independent from or in conjunction with the bottom magneticrotor 112B. As mentioned above, the strength of the magnetic field, andthus the amount of heat imparted into the blank 102, can be adjusted inother or additional ways.

In certain examples, the magnetic rotors 112A-B may be adjustedlaterally (see arrows 120 in FIG. 1). Lateral movement can control thepercentage of the surface of the blank 102 covered by a particular rotor112A-B, and therefore the amount and location of the heat imparted intothe blank 102. In certain examples, the magnetic rotors 112A-B may belaterally adjusted to control the temperature profile in the blank 102.For example, in some cases, edges of the blank 102 may be heated morerapidly than non-edge portions of the blank 102, and the magnetic rotors112A-B may be laterally adjusted such that the temperature variation inthe blank 102 is reduced. In various examples, the magnetic rotors112A-B may be longitudinally adjustable to control the gap betweenadjacent sets of magnetic rotors 112 (see arrows 124 in FIG. 2) and/orto control the longitudinal position of the magnetic rotors 112 relativeto the blank 102.

In some examples, the top magnetic rotor 112A and the bottom magneticrotor 112B rotate in the same direction, although they need not. Forexample, in some cases, the top magnetic rotor 112A and the bottommagnetic rotor 112B may rotate in opposite directions. In variousexamples, the magnetic rotors 112A-B of one set of magnetic rotors mayrotate in the same or in a different direction as the correspondingmagnetic rotors 112A-B of another set of magnetic rotors. The magneticrotors 112A-B may rotate at various rotational speeds, such as fromabout 100 rpm to about 5000 rpm. In one non-limiting example, themagnetic rotors 112A-B rotate at about 1800 revolutions per minute,although various other rotational speeds may be utilized. As themagnetic rotors 112A-B rotate, the magnets induce a magnetic field intothe blank 102 such that the blank 102 is heated. In various examples,through the rotation of the magnetic rotors 112, the heater 104 isconfigured to heat the blank 102.

In certain examples with multiple magnetic rotors 112A-B, the magneticrotors 112A-B may optionally be controlled such that the amount oftemperature rise of the blank 102 imparted by each magnetic rotor 112A-Bis limited. In some examples, in addition to heating the blank 102,rotating the magnetic rotors 112A-B may also provide verticalstabilization that allows the blank 102 to pass over and/or between themagnetic rotors 112 without contacting the magnetic rotors 112A-B (e.g.,the magnetic rotors 112A-B levitate or float the blank 102). Forexample, in some cases, the magnetic rotors 112A-B impart a force thatis perpendicular or substantially perpendicular to a surface of theblank 102 to float the blank 102 and minimize and/or eliminate contactbetween the rotors 112A-B and the blank 102.

In other cases, the blank 102 may be supported by a support 118 in theheater 104. The support 118 may be a platform, brackets, conveyor, orvarious other suitable support structures. In some cases, the support118 is configured to laterally position the blank 102 relative to theheater 104, the second heater 110, or both heaters 104 and 110. Incertain cases, the support 118 may advance the blank 102 through theheater 104 and optionally through the second heater 110, although itneed not.

In various examples, the heater 104 is configured to heat the blank 102for a predetermined time period. In various examples, the predeterminedtime period may include a heat up time and a soaking time, although itneed not. In some non-limiting examples, the heater 104 heats the blank102 for about 30 seconds to 20 minutes. In one non-limiting example, thepredetermined time period is from about 30 seconds to about 6 minutes.In other examples, the predetermined time period may be greater than 20minutes. In one non-limiting example where the heater 104 is the entireapparatus (e.g., the second heater 110 is omitted), the predeterminedtime period may include the heat up time and the soaking time. In otherexamples, where the second heater 110 is included, the predeterminedtime period may include the time that the blank 102 is heated by boththe heater 104 and the second heater 110, although it need not.

In various examples, the heater 104 heats the blank 102 to apredetermined temperature. In some non-limiting examples, thepredetermined temperature is a solutionizing temperature of the blank102, although it need not be. For example, in other non-limiting cases,the predetermined temperature may be a warming temperature, or variousother temperatures. In other examples, the predetermined temperature isless than the solutionizing temperature of the blank. In certainnon-limiting examples, the heater 104 heats the blank 102 to atemperature of from about 200° C. to about 600° C. In other examples,the heater 104 may heat the blank 102 to a temperature of less than 200°C. or greater than 600° C. depending on particular application. As onenon-limiting example, the heater 104 may heat a 7xxx series aluminumalloy blank 102 to a temperature of from about 400° C. to about 500° C.As another non-limiting example, the heater 104 may heat a 6xxx seriesaluminum alloy blank to a temperature of from about 400° C. to about600° C. As a further non-limiting example, the heater 104 may beprovided for warm forming of metal blanks or sheets having varioustempers. As one non-limiting example, the heater 104 may heat a T6 sheetto a temperature of from about 200° C. or 300° C. depending on theparticular alloys of the sheet.

In various examples, the blank 102 can make multiple passes through theheater 104 (or through each set of magnetic rotors 112A-B of the heater104). In various examples, the blank 102 can make an odd number ofpasses through the heater 104 (or each set of magnetic rotors 112A-B ofthe heater 104). For example, the blank 102 can make one pass throughthe heater 104, three passes through the heater 104, five passes throughthe heater 104, seven passes through the heater 104, or more than sevenpasses through the heater 104. In certain examples, two or more sets ofmagnetic rotors 112A-B may be arranged in various suitableconfigurations such that the blank 102 makes a single pass (or anydesired number of passes) through the heater 104. In other examples, theblank 102 can make an even number of passes through the heater 104 (oreach set of magnetic rotors 112A-B of the heater 104) depending on aconfiguration and arrangement of the magnetic rotors 112A-B.

In some optional cases, the hot forming system 100 includes the secondheater 110. In various examples, the second heater 110 is arranged suchthat the blank 102 is first heated by the heater 104 and then heated bythe second heater 110. In such examples, the second heater 110 mayoptionally be used for homogenizing the blank temperature, such as theblank solutionizing temperature. In other examples, the order of theheater 104 and the second heater 110 may be reversed. The second heater110 includes a blank-receiving area 114. In some cases, the support 118may support the blank 102 when the blank is in the blank-receiving area114. In other examples, a different support from the support 118 maysupport the blank 102. In some examples, the second heater 110 may be agas-powered heater (direct such as direct flame impingement orindirect), a roller furnace, an induction heater, an infrared heater, anelectric furnace, or various other suitable types of heaters. In variousother examples, the second heater 110 may be similar to the heater 104and include one or more magnetic rotors 112. As one non-limitingexample, the second heater 110 may be a roller furnace that includesmagnetic rotors 112, which may significantly shorten the length of theroller furnace. In various examples, the second heater 110 may heat theblank 102 for a predetermined time period. As previously described, insome cases, the predetermined time period includes the time that theblank 102 is heated by both the heater 104 and the second heater 110,although it need not. In certain examples, the second heater 110 mayheat the blank 102 for a time period of from about 30 seconds to about20 minutes.

In certain examples, by providing the second heater 110 with the heater104, the temperature profile in the blank 102 can be controlled. Forexample, in some cases, the heater 104 may heat the blank 102 to a firsttemperature that is less than the solutionizing temperature, and thesecond heater 110 may heat the blank 102 from the first temperature tothe solutionizing temperature. In some examples, the heater 104 may heatthe blank 102 for a first time period and the second heater 110 may heatthe blank for a second time period. In some examples, the amount of timethat the heater 104 heats the blank 102 may depend on various factorsincluding, but not limited to, a size and/or thickness of the blank 102,a number of magnetic rotors 112, the number of passes of the blank 102through the heater 104, the rotating speed of the magnetic rotors 112,the rotating direction of the magnetic rotors 112, a distance from themagnetic rotors 112 to the blank 102, or various other factors. Incertain examples, the heater 104 heats the blank 102 such thatsignificant distortions are not introduced to the blank 102. As onenon-limiting example, the heater 104 may heat the blank 102 for a timeperiod of from about 1 second to about 30 seconds. In other examples,the heater 104 may heat the blank 102 for more than 30 seconds.

In other examples, the second heater 110 may be provided to control thetemperature profile of the blank 102. As one non-limiting example, insome cases, heating the blank 102 with the heater 104 may cause theblank 102 to have a varied temperature profile. For example, in somenon-limiting cases, the edges of the blank 102 may have a temperaturethat is greater than a temperature of a non-edge portion of the blank102. In some cases, the second heater 110 may heat the blank 102 afterthe heater 104 to control the temperature profile of the blank 102. Asone non-limiting example, the second heater 110 may heat the blank 102such that the blank 102 has a uniform temperature profile.

The blank mover 108 may be provided at various locations to move theblank 102 between various components of the hot forming system 100. Forexample, in some cases, the blank mover 108 is provided between thesecond heater 110 and the hot forming press 106 to move the blank 102between the second heater 110 and the hot forming press 106. Similarly,the blank mover 108 (or another blank mover 108) may be provided betweenthe heater 104 and the second heater 110 to move the blank 102 from theheater 104 to the second heater 110.

The blank mover 108 includes a support 130 for supporting the blank 102.In various components, the blank mover 108 may be various suitablemechanisms or devices for moving the blank 102 between variouscomponents of the hot forming system 100. As one non-limiting example,the blank mover 108 may include a robotic arm that supports and movesthe blank 102. In other examples, other types of blank movers 108 may beutilized. As such, the number and type of blank mover 108 should not beconsidered limiting on the current disclosure.

The hot forming press 106 includes a die 116 and a tool 117. The die 116has a predetermined shape such that when the blank 102 is positionedwithin the hot forming press 106, the tool 117 moves towards the die 116and forms the blank 102 into the shape defined by the die 116. In someexamples, the hot forming press 106 may hot form the blank 102 at apredetermined press speed. In some non-limiting examples, thepredetermined press speed may be from about 100 mm/second to about 400mm/second, although various other press speeds may be utilized. Invarious examples, the hot forming press 106 may be a hydraulic press,mechanical press, servo-controlled press, or various other suitabletypes of presses. In some examples, the die 116 is a water-cooled die.In some cases, the die 116 could be a warm die and/or have acontrollable temperature profile. As one non-limiting example, in somecases, such as during forming steel, the die 116 may be heated in somezones of the die 116 and cooled in other zones of the die 116 in orderto achieve different final properties in different part locations whenthe blank 102 is formed into the shape defined by the die 116. Aspreviously described, in some examples, the system 100 may be a warmforming system. In such cases, the press 106 is a warm forming press,and the forming temperature is not as high as with the hot formingpress. In some cases, the system 100 may include blow forming atelevated temperatures in addition to or in place of the hot formingpress 106 having the die 116. During blow forming, the preheated blank102 is introduced to the tool and then deformed with hot gas at variouspressures.

In certain examples, the hot forming system 100 includes various sensorsor monitors 131 at various positions relative to the heater 104. Thesesensors 131 may detect and monitor a position of the blank 102, movementof the blank 102, a temperature of the blank 102, a temperaturedistribution across the blank 102, and/or various other informationabout the blank 102 as it is processed. In some examples, theinformation gathered by the sensors may be used by a controller toadjust the magnetic rotors 112A-B (e.g., rotational speed, direction ofrotation, distance from blank 102, etc.) and thereby control heating ofthe blank 102. In some examples, the controller may adjust the number ofpasses of the blank 102 through the heater 104.

As one example, the heater 104 may be controlled to reduce or preventoverheating of the blank 102 and/or to control activation anddeactivation of the magnetic rotors 112A-B. For example, the magneticrotors 112A-B may be deactivated (i.e., stop rotating) if a blank 102 isnot within the heater 104, after the blank 102 has been heated for thepredetermined time period, after the blank 102 has been heated to apredetermined temperature, or various other factors. Similarly, themagnetic rotors 112A-B may start rotating again or continue to rotate(and thus start heating the blank 102 again) based on if a blank isproximate the heater 104, the temperature of the blank 102 being lessthan the predetermined temperature, the blank 102 being heated for atime period less than the predetermined time period, or various otherfactors. Accordingly, through the magnetic rotors 112A-B, the heater 104may rapidly heat or stop heating the blank 102.

As another example, the heaters 104 and/or 110 may be controlled toensure a uniform or desired temperature profile of the blank 102. Forexample, the sensor or monitor 131 may detect a temperature of the blank102 as it exits the heater 104. Based on the detected temperature, themagnetic rotors 112 may be controlled (e.g., by adjusting power input tothe magnetic rotors 112, speed of the magnetic rotors 112A-B, distanceof the magnetic rotors 112A-B from the blank 102, etc.) and/or thesecond heater 110 may be controlled to control the temperature of theblank 102 and/or temperature across the blank 102.

As a further example, the heater 104 may be controlled to accommodatedifferent types of blanks 102. For example, depending on the type ofblank 102 and/or desired process or product requirements, the blank 102may be heated by the heater 104 and/or the heater 110 at differentprocessing times, processing temperatures, etc. By controlling themagnetic rotors 112A-B, the temperature can be changed more quickly thanconventional heaters.

Referring to FIGS. 1 and 2, a method of hot forming the metal blank 102is also disclosed. In various examples, the method includes receivingthe blank 102 of a metal substrate at the heater 104. In somenon-limiting examples, the blank 102 includes aluminum or an aluminumalloy.

The method includes positioning the blank 102 adjacent to the magneticrotors 112A-B of the heater 104 and rotating the magnetic rotors 112A-Bto induce a magnetic field into the blank 102 to heat the blank 102. Insome examples, the blank 102 is heated for a predetermined time period.For example, in some non-limiting examples, the blank 102 is heated forabout 30 seconds about 20 minutes In some examples, the predeterminedtime period may depend on a size and/or thickness of the blank 102 amongother factors. In other examples, the blank 102 is heated to apredetermined temperature. For example, in some non-limiting cases, theblank 102 is heated to a temperature of from about 200° C. to about 600°C. In some examples, the predetermined temperature is a solutionizingtemperature of the blank 102. The solutionizing temperature may dependon the particular material composition of the blank 102. As onenon-limiting example, the heater 104 may heat a 7xxx series aluminumalloy blank 102 to a temperature of from about 400° C. to about 500° C.As another non-limiting example, the heater 104 may heat a 6xxx seriesaluminum alloy blank to a temperature of from about 400° C. to about600° C. In some examples, the solutionizing temperature may depend on asize and/or thickness of the blank 102 among other factors.

In certain cases, positioning the blank 102 includes positioning theblank 102 on the support 118. In some examples, the method includesmoving the blank 102 laterally with the support 118 relative to themagnetic rotors 112A-B while maintaining the lateral position of themagnetic rotors 112A-B. In other examples, positioning the blank 102includes positioning the blank 102 on the support 118 and lateral movingthe magnetic rotors 112A-B relative to the blank 102 while maintainingthe lateral position of the blank 102.

In some examples, the method includes adjusting the magnetic field toadjust an amount of heat induced into the blank 102 by the magneticrotors 112A-B. In certain examples, adjusting the magnetic fieldincludes adjusting a rotational speed of the magnetic rotors 112A-B,adjusting a direction of rotation of the magnetic rotors 112A-B,adjusting a vertical position of the magnetic rotors 112A-B relative tothe blank 102, adjusting a lateral position of the magnetic rotors112A-B relative to the blank 102, and/or adjusting a longitudinalposition of the magnetic rotors 112A-B relative to the blank 102. Invarious cases, the method includes detecting a temperature of the blank102, such as with the sensor 131, comparing the detected temperature toa predetermined temperature, and adjusting the magnetic rotor 112A-B toadjust the heating of the blank 102 such that the detected temperaturematches the predetermined temperature. In various examples, positioningthe blank 102 includes positioning the blank 102 a predetermineddistance from the magnetic rotors 112A-B.

In various examples, the method optionally includes removing the blank102 from the heater 104, positioning the blank 102 in the second heater110, and heating the blank 102 with the second heater 110. In variousexamples, heating the blank 102 with the second heater 110 includescontrolling a temperature profile of the blank 102. In certain examples,heating the blank 102 with the second heater 110 includes heating theblank 102 to the solutionizing temperature of the blank 102. In somecases, removing the blank 102 from the heater 104 and positioning theblank 102 in the second heater 110 includes moving the blank on thesupport 118. In some examples, the support 118 is a conveyor or othersuitable support for moving the blank 102 from the heater 104 to thesecond heater 110.

In some examples, the method includes removing the blank 102 from theheater 104 (or heater 110) after the heater 104 (or heater 110) heatsthe blank 102. In certain examples, the blank 102 is removed after thepredetermined time period and/or after the blank 102 is at thepredetermined temperature. In certain examples, the method includesusing the blank mover 108 to move the blank 102 from the heater 104 tothe hot forming press 106. In some cases, the method includes hotforming the blank 102 with the hot forming press 106. In certain cases,hot forming the blank 102 includes positioning the blank 102 on the die116 of the hot forming press 106 and pressing the blank 102 with the hotforming press 106 such that the die 116 shapes the blank 102.

A collection of exemplary embodiments, including at least someexplicitly enumerated as “ECs” (Example Combinations), providingadditional description of a variety of embodiment types in accordancewith the concepts described herein are provided below. These examplesare not meant to be mutually exclusive, exhaustive, or restrictive; andthe invention is not limited to these example embodiments but ratherencompasses all possible modifications and variations within the scopeof the issued claims and their equivalents.

EC 1. A method comprising: receiving a blank of a metal substrate at aheater, wherein the heater comprises a magnetic rotor; positioning theblank adjacent the magnetic rotor of the heater; and rotating themagnetic rotor to induce a magnetic field in the blank to heat the blankfor a predetermined time period.

EC 2. The method of any of the preceding or subsequent examplecombinations, wherein rotating the magnetic to induce the magnetic fieldin the blank to heat the blank for the predetermined time periodcomprises heating the blank to a predetermined temperature, and whereinthe predetermined temperature is a solutionizing temperature of theblank.

EC 3. The method of any of the preceding or subsequent examplecombinations, wherein the predetermined temperature is from about 200°C. to about 600° C.

EC 4. The method of any of the preceding or subsequent examplecombinations, further comprising removing the blank from the heaterafter the predetermined time period.

EC 5. The method of any of the preceding or subsequent examplecombinations, wherein removing the blank comprises using a mover toremove the blank from the heater to a hot forming press.

EC 6. The method of any of the preceding or subsequent examplecombinations, further comprising hot forming the blank into apredetermined shape with the hot forming press.

EC 7. The method of any of the preceding or subsequent examplecombinations, wherein the hot forming press comprises a water-cooleddie.

EC 8. The method of any of the preceding or subsequent examplecombinations, wherein positioning the blank comprises moving the blankwith a mover relative to the magnetic rotor while maintaining a lateralposition of the magnetic rotor.

EC 9. The method of any of the preceding or subsequent examplecombinations, wherein positioning the blank comprises moving themagnetic rotor relative to the metal blank while maintaining the lateralposition of the metal blank.

EC 10. The method of any of the preceding or subsequent examplecombinations, further comprising adjusting the magnetic field to adjustan amount of heat induced by the magnetic rotor.

EC 11. The method of any of the preceding or subsequent examplecombinations, wherein adjusting the magnetic field comprises at leastone of adjusting a rotational speed of the magnetic rotor, adjusting adirection of rotation of the magnetic rotor, adjusting a verticalposition of the magnetic rotor relative to the blank, adjusting alateral position of the magnetic rotor relative to the blank, oradjusting a longitudinal position of the magnetic rotor relative to theblank.

EC 12. The method of any of the preceding or subsequent examplecombinations, wherein adjusting the magnetic field comprises: detectinga temperature of the blank; comparing the detected temperature to apredetermined temperature; and adjusting the magnetic rotor to adjustthe heating of the blank such that the detected temperature matches thepredetermined temperature.

EC 13. The method of any of the preceding or subsequent examplecombinations, wherein positioning the blank adjacent the magnetic rotorcomprises positioning the blank a predetermined distance from themagnetic rotor.

EC 14. The method of any of the preceding or subsequent examplecombinations, wherein the magnetic rotor is a top magnetic rotor,wherein the heater further comprises a bottom magnetic rotor verticallyoffset from the top magnetic rotor, wherein passing the blank adjacent amagnetic rotor comprises passing the blank through a gap defined betweenthe top magnetic rotor and the bottom magnetic rotor, and whereinrotating the magnetic rotor comprises rotating the top magnetic rotorand the bottom magnetic rotor to heat the blank.

EC 15. The method of any of the preceding or subsequent examplecombinations, wherein the predetermined time period is from about 30seconds to about 20 minutes.

EC 16. The method of any of the preceding or subsequent examplecombinations, wherein the heater is a first heater, and wherein themethod further comprises: removing the blank from the first heater afterthe predetermined time period; positioning the blank in a second heater;and heating the blank with the second heater.

EC 17. The method of any of the preceding or subsequent examplecombinations, wherein heating the blank with the second heater furthercomprises controlling a temperature profile of the blank.

EC 18. The method of any of the preceding or subsequent examplecombinations, wherein the second heater comprises a gas-powered heater,an infrared heater, a roller furnace, an electric furnace, or aninduction heater.

EC 19. The method of any of the preceding or subsequent examplecombinations, wherein heating the blank with the second heater comprisesheating the blank to a solutionizing temperature of the blank.

EC 20. The method of any of the preceding or subsequent examplecombinations, wherein removing the blank from the first heater andpositioning the blank in the second heater comprises moving the blankwith a mover.

EC 21. The method of any of the preceding or subsequent examplecombinations, wherein the mover is a conveyor.

EC 22. The method of any of the preceding or subsequent examplecombinations, wherein the blank comprises aluminum.

EC 23. A method comprising: receiving a blank of a metal substrate at aheater, wherein the heater comprises a magnetic rotor; positioning theblank adjacent the magnetic rotor of the heater; rotating the magneticrotor to induce a magnetic field in the blank to heat the blank; andremoving the blank from the heater when the blank is at a predeterminedtemperature.

EC 24. The method of any of the preceding or subsequent examplecombinations, wherein the predetermined temperature is a solutionizingtemperature of the blank.

EC 25. The method of any of the preceding or subsequent examplecombinations, wherein the predetermined temperature is from about 200°C. to about 600° C.

EC 26. The method of any of the preceding or subsequent examplecombinations, wherein removing the blank comprises using a mover toremove the blank from the heater to a hot forming press.

EC 27. The method of any of the preceding or subsequent examplecombinations, further comprising hot forming the blank with the hotforming press.

EC 28. The method of any of the preceding or subsequent examplecombinations, wherein the hot forming press comprises a water-cooleddie.

EC 29. The method of any of the preceding or subsequent examplecombinations, wherein positioning the blank comprises moving the blankwith a mover relative to the magnetic rotor while maintaining a lateralposition of the magnetic rotor.

EC 30. The method of any of the preceding or subsequent examplecombinations, wherein positioning the blank comprises moving themagnetic rotor relative to the metal blank while maintaining the lateralposition of the metal blank.

EC 31. The method of any of the preceding or subsequent examplecombinations, further comprising adjusting the magnetic field to adjustan amount of heat induced by the magnetic rotor.

EC 32. The method of any of the preceding or subsequent examplecombinations, wherein adjusting the magnetic field comprises at leastone of adjusting a rotational speed of the magnetic rotor, adjusting adirection of rotation of the magnetic rotor, adjusting a verticalposition of the magnetic rotor relative to the blank, adjusting alateral position of the magnetic rotor relative to the blank, oradjusting a longitudinal position of the magnetic rotor relative to theblank.

EC 33. The method of any of the preceding or subsequent examplecombinations, wherein adjusting the magnetic field comprises: detectinga temperature of the blank; comparing the detected temperature to apredetermined temperature; and adjusting the magnetic rotor to adjustthe heating of the blank such that the detected temperature matches thepredetermined temperature.

EC 34. The method of any of the preceding or subsequent examplecombinations, wherein positioning the blank adjacent the magnetic rotorcomprises positioning the blank a predetermined distance from themagnetic rotor.

EC 35. The method of any of the preceding or subsequent examplecombinations, wherein the magnetic rotor is a top magnetic rotor,wherein the heater further comprises a bottom magnetic rotor verticallyoffset from the top magnetic rotor, wherein passing the blank adjacent amagnetic rotor comprises passing the blank through a gap defined betweenthe top magnetic rotor and the bottom magnetic rotor, and whereinrotating the magnetic rotor comprises rotating the top magnetic rotorand the bottom magnetic rotor to heat the blank.

EC 36. The method of any of the preceding or subsequent examplecombinations, wherein the heater is a first heater, and wherein themethod further comprises: removing the blank from the first heater afterthe predetermined time period; positioning the blank in a second heater;and heating the blank with the second heater.

EC 37. The method of any of the preceding or subsequent examplecombinations, wherein heating the blank with the second heater furthercomprises controlling a temperature profile of the blank.

EC 38. The method of any of the preceding or subsequent examplecombinations, wherein the second heater comprises a gas-powered heater,an infrared heater, a roller furnace, an electric furnace, or aninduction heater.

EC 39. The method of any of the preceding or subsequent examplecombinations, wherein heating the blank with the second heater comprisesheating the blank to a solutionizing temperature of the blank.

EC 40. The method of any of the preceding or subsequent examplecombinations, wherein removing the blank from the first heater andpositioning the blank in the second heater comprises moving the blankwith a mover.

EC 41. The method of any of the preceding or subsequent examplecombinations, wherein the mover is a conveyor.

EC 42. The method of any of the preceding or subsequent examplecombinations, wherein the blank comprises aluminum.

EC 43. A hot forming system comprising: a heater comprising a magneticrotor, wherein the heater is configured to: receive a blank of a metalsubstrate adjacent the magnetic rotor; and rotate the magnetic rotor toinduce a magnetic field in the blank to heat the blank.

EC 44. The hot forming system of any of the preceding or subsequentexample combinations, wherein the heater is configured to heat the blankfor a predetermined time period.

EC 45. The hot forming system of any of the preceding or subsequentexample combinations, wherein the predetermined time period of heatingthe blank is from about 30 seconds to about 20 minutes.

EC 46. The hot forming system of any of the preceding or subsequentexample combinations, wherein the heater is configured to heat the blankto a predetermined temperature.

EC 47. The hot forming system of any of the preceding or subsequentexample combinations, wherein the predetermined temperature is asolutionizing temperature of the blank.

EC 48. The hot forming system of any of the preceding or subsequentexample combinations, further comprising a mover configured to move theblank from the heater to a hot forming press.

EC 49. The hot forming system of any of the preceding or subsequentexample combinations, further comprising a hot forming press.

EC 50. The hot forming system of any of the preceding or subsequentexample combinations, wherein the hot forming press comprises awater-cooled die.

EC 51. The hot forming system of any of the preceding or subsequentexample combinations, wherein the heater further comprises a mover thatis configured to laterally position the blank relative to the magneticrotor.

EC 52. The hot forming system of any of the preceding or subsequentexample combinations, wherein the mover comprises a conveyor.

EC 53. The hot forming system of any of the preceding or subsequentexample combinations, wherein the magnetic rotor is laterally movablerelative to the blank.

EC 54. The hot forming system of any of the preceding or subsequentexample combinations, wherein at least one characteristic of themagnetic rotor is adjustable such that the magnetic field induced intothe blank is adjustable to adjust an amount of heat induced by themagnetic rotor.

EC 55. The hot forming system of any of the preceding or subsequentexample combinations, wherein the at least one characteristic comprisesa rotational speed of the magnetic rotor, a direction of rotation of themagnetic rotor, a vertical position of the magnetic rotor relative tothe blank, a lateral position of the magnetic rotor relative to theblank, or a longitudinal position of the magnetic rotor relative to theblank.

EC 56. The hot forming system of any of the preceding or subsequentexample combinations, further comprising: a sensor configured to detecta temperature of the blank; and a controller in communication, whereinthe controller is configured to adjust the magnetic rotor based on thedetected temperature of the blank.

EC 57. The hot forming system of any of the preceding or subsequentexample combinations, wherein the magnetic rotor is a top magneticrotor, wherein the heater further comprises a bottom magnetic rotorvertically offset from the top magnetic rotor such that a gap is definedbetween the bottom magnetic rotor and the top magnetic rotor, andwherein the heater is configured to receive the blank in the gap.

EC 58. The hot forming system of any of the preceding or subsequentexample combinations, wherein the heater is a first heater, and whereinthe hot forming system further comprises: a second heater that isconfigured to: receive the blank from the first heater; and heat theblank.

EC 59. The hot forming system of any of the preceding or subsequentexample combinations, wherein the second heater is further configured tocontrol a temperature profile of the blank.

EC 60. The hot forming system of any of the preceding or subsequentexample combinations, wherein the second heater comprises a gas-poweredheater, an infrared heater, a roller furnace, an electric furnace, or aninduction heater.

EC 61. The hot forming system of any of the preceding or subsequentexample combinations, further comprising: a hot forming press; and amover, wherein the mover is configured to move the blank from the secondheater to the hot forming press, and wherein the hot forming press isconfigured to shape the blank.

EC 62. A method comprising: receiving a blank of a metal substrate at aheater, wherein the heater comprises a magnetic rotor; positioning theblank adjacent the magnetic rotor of the heater; and rotating themagnetic rotor to induce a magnetic field in the blank to heat the blankfor a predetermined time period.

EC 63. The method of any of the preceding or subsequent examplecombinations, wherein rotating the magnetic to induce the magnetic fieldin the blank to heat the blank for the predetermined time periodcomprises heating the blank to a predetermined temperature, and whereinthe predetermined temperature is temperature is from about 200° C. toabout 600° C.

EC 64. The method of any of the preceding or subsequent examplecombinations, further comprising: removing the blank from the heaterafter the predetermined time period and moving the blank to a hotforming press; and hot forming the blank into a predetermined shape withthe hot forming press.

EC 65. The method of any of the preceding or subsequent examplecombinations, wherein positioning the blank comprises moving the blankwith a mover relative to the magnetic rotor while maintaining a lateralposition of the magnetic rotor.

EC 66. The method of any of the preceding or subsequent examplecombinations, wherein positioning the blank comprises moving themagnetic rotor relative to the metal blank while maintaining the lateralposition of the metal blank.

EC 67. The method of any of the preceding or subsequent examplecombinations, further comprising adjusting the magnetic field to adjustan amount of heat induced by the magnetic rotor, wherein adjusting themagnetic field comprises at least one of adjusting a rotational speed ofthe magnetic rotor, adjusting a direction of rotation of the magneticrotor, adjusting a vertical position of the magnetic rotor relative tothe blank, adjusting a lateral position of the magnetic rotor relativeto the blank, or adjusting a longitudinal position of the magnetic rotorrelative to the blank.

EC 68. The method of any of the preceding or subsequent examplecombinations, wherein the magnetic rotor is a top magnetic rotor,wherein the heater further comprises a bottom magnetic rotor verticallyoffset from the top magnetic rotor, wherein passing the blank adjacent amagnetic rotor comprises passing the blank through a gap defined betweenthe top magnetic rotor and the bottom magnetic rotor, and whereinrotating the magnetic rotor comprises rotating the top magnetic rotorand the bottom magnetic rotor to heat the blank.

EC 69. The method of any of the preceding or subsequent examplecombinations, wherein the predetermined time period is from about 30seconds to about 20 minutes.

EC 70. The method of any of the preceding or subsequent examplecombinations, wherein the heater is a first heater, and wherein themethod further comprises: removing the blank from the first heater afterthe predetermined time period; positioning the blank in a second heater;and heating the blank with the second heater to a predeterminedtemperature.

EC 71. The method of any of the preceding or subsequent examplecombinations, wherein the second heater comprises a gas-powered heater,an infrared heater, a roller furnace, an electric furnace, or aninduction heater.

EC 72. The method of any of the preceding or subsequent examplecombinations, the predetermined temperature is a solutionizingtemperature of the blank, and wherein heating the blank with the secondheater comprises further comprises controlling a temperature profile ofthe blank.

EC 73. The method of any of the preceding or subsequent examplecombinations, wherein the blank comprises aluminum.

EC 74. A method comprising: receiving a blank of a metal substrate at aheater, wherein the heater comprises a magnetic rotor; positioning theblank adjacent the magnetic rotor of the heater; rotating the magneticrotor to induce a magnetic field in the blank to heat the blank; andremoving the blank from the heater when the blank is at a predeterminedtemperature.

EC 75. The method of any of the preceding or subsequent examplecombinations, wherein the predetermined temperature is from about 200°C. to about 600° C.

EC 76. The method of any of the preceding or subsequent examplecombinations, wherein the heater is a first heater, and wherein themethod further comprises: removing the blank from the first heater afterthe predetermined time period; positioning the blank in a second heater;heating the blank with the second heater for a second predetermined timeperiod; removing the blank from the second heater; and hot forming theblank with a hot forming press.

EC 77. The method of any of the preceding or subsequent examplecombinations, wherein heating the blank with the second heater comprisesheating the blank to a solutionizing temperature of the blank.

EC 78. A hot forming system comprising: a heater comprising a magneticrotor, wherein the heater is configured to: receive a blank of a metalsubstrate adjacent the magnetic rotor; and rotate the magnetic rotor toinduce a magnetic field in the blank to heat the blank.

EC 79. The hot forming system of any of the preceding or subsequentexample combinations, wherein the heater is a first heater, and whereinthe hot forming system further comprises: a second heater that isconfigured to: receive the blank from the first heater; and heat theblank.

EC 80. The hot forming system of any of the preceding or subsequentexample combinations, wherein the second heater comprises a gas-poweredheater, an infrared heater, a roller furnace, an electric furnace, or aninduction heater.

EC 81. The hot forming system of any of the preceding or subsequentexample combinations, further comprising: a hot forming press; and amover, wherein the mover is configured to move the blank from the heaterto the hot forming press, and wherein the hot forming press isconfigured to shape the blank.

The above-described aspects are merely possible examples ofimplementations, merely set forth for a clear understanding of theprinciples of the present disclosure. Many variations and modificationscan be made to the above-described embodiment(s) without departingsubstantially from the spirit and principles of the present disclosure.All such modifications and variations are intended to be included hereinwithin the scope of the present disclosure, and all possible claims toindividual aspects or combinations of elements or steps are intended tobe supported by the present disclosure. Moreover, although specificterms are employed herein, as well as in the claims that follow, theyare used only in a generic and descriptive sense, and not for thepurposes of limiting the described invention, nor the claims thatfollow.

That which is claimed:
 1. A method comprising: receiving a blank of ametal substrate at a heater, wherein the heater comprises a magneticrotor, and wherein the heater is upstream from a first hot forming pressof a hot forming system; positioning the blank adjacent the magneticrotor of the heater and in a non-contacting configuration with themagnetic rotor; rotating the magnetic rotor to induce a magnetic fieldin the blank to heat the blank for a predetermined time period; removingthe blank from the heater after the predetermined time period and movingthe blank to the first hot forming press; and shaping the blank into apredetermined shape with the first hot forming press.
 2. The method ofclaim 1, wherein rotating the magnetic rotor to induce the magneticfield in the blank to heat the blank for the predetermined time periodcomprises heating the blank to a predetermined temperature, and whereinthe predetermined temperature is from about 200° C. to about 600° C. 3.The method of claim 1, wherein positioning the blank comprises movingthe blank with a mover relative to the magnetic rotor while maintaininga lateral position of the magnetic rotor.
 4. The method of claim 1,wherein positioning the blank comprises moving the magnetic rotorrelative to the blank while maintaining a lateral position of the blank.5. The method of claim 1, further comprising adjusting the magneticfield to adjust an amount of heat induced by the magnetic rotor, whereinadjusting the magnetic field comprises at least one of adjusting arotational speed of the magnetic rotor, adjusting a direction ofrotation of the magnetic rotor, adjusting a vertical position of themagnetic rotor relative to the blank, adjusting a lateral position ofthe magnetic rotor relative to the blank, or adjusting a longitudinalposition of the magnetic rotor relative to the blank.
 6. The method ofclaim 1, wherein the magnetic rotor is a top magnetic rotor, wherein theheater further comprises a bottom magnetic rotor vertically offset fromthe top magnetic rotor, wherein passing the blank adjacent a magneticrotor comprises passing the blank through a gap defined between the topmagnetic rotor and the bottom magnetic rotor, and wherein rotating themagnetic rotor comprises rotating the top magnetic rotor and the bottommagnetic rotor to heat the blank.
 7. The method of claim 1, wherein thepredetermined time period is from about 30 seconds to about 20 minutes.8. The method of claim 1, wherein the heater is a first heater, andwherein the method further comprises: removing the blank from the firstheater after the predetermined time period; positioning the blank in asecond heater upstream from the first hot forming press; and heating theblank with the second heater to a predetermined temperature.
 9. Themethod of claim 8, wherein the second heater comprises a gas-poweredheater, an infrared heater, a roller furnace, an electric furnace, or aninduction heater.
 10. The method of claim 8, wherein the predeterminedtemperature is a solutionizing temperature of the blank, and whereinheating the blank with the second heater comprises further comprisescontrolling a temperature profile of the blank.
 11. The method of claim1, wherein the blank comprises aluminum or an aluminum alloy.
 12. Themethod of claim 1, wherein an axis of rotation of the magnetic rotor isparallel to a direction of travel of the blank through the heater.
 13. Amethod comprising: receiving a blank of a metal substrate at a firstheater, wherein the first heater comprises a magnetic rotor; positioningthe blank adjacent the magnetic rotor of the first heater; rotating themagnetic rotor to induce a magnetic field in the blank to heat theblank; removing the blank from the first heater when the blank is at apredetermined temperature and after a first predetermined time period;positioning the blank in a second heater; heating the blank with thesecond heater for a second predetermined time period; removing the blankfrom the second heater; and hot forming the blank with a hot formingpress.
 14. The method of claim 13, wherein the predetermined temperatureis from about 200° C. to about 600° C.
 15. The method of claim 13,wherein heating the blank with the second heater comprises heating theblank to a solutionizing temperature of the blank.
 16. A hot formingsystem comprising: a heater comprising a magnetic rotor; and a first hotforming press of the hot forming system, wherein the heater is upstreamfrom the first hot forming press and is configured to: receive a blankof a metal substrate adjacent the magnetic rotor and in a non-contactingconfiguration with the magnetic rotor; and rotate the magnetic rotor toinduce a magnetic field in the blank to heat the blank, wherein the hotforming press is configured to receive the blank from the heater after apredetermined time period and shape the blank into a predeterminedshape.
 17. The hot forming system of claim 16, wherein the heater is afirst heater, and wherein the hot forming system further comprises: asecond heater upstream from the first hot forming press and that isconfigured to: receive the blank from the first heater; and heat theblank.
 18. The hot forming system of claim 17, wherein the second heatercomprises a gas-powered heater, an infrared heater, a roller furnace, anelectric furnace, or an induction heater.
 19. The hot forming system ofclaim 16, further comprising: a mover, wherein the mover is configuredto move the blank from the heater to the first hot forming press. 20.The hot forming system of claim 16, wherein an axis of rotation of themagnetic rotor is parallel to a direction of travel of the blank throughthe heater.